Fabrication of metal interconnect for semiconductor device

ABSTRACT

Disclosed is a method of fabricating a semiconductor device comprising the step of defining metal interconnect features in a metal layer so that a metal feature having a size substantially larger than a predetermined feature size comprises an array of metal features. Each of the metal features in the array has a size not substantially larger than the predetermined feature size.

The Government has rights in this invention pursuant to Contract No. F33615-81-C-1527 awarded by the Department of the Air Force.

This application is a continuation of application Ser. No. 658,104, filed Oct. 5, 1984, now abandoned.

BACKGROUND OF THE INVENTION

The present invention relates to planarization of integrated circuits. More particularly, the present invention relates to use of particular metalization features in order to planarize dielectric layers in semiconductor device VLSI integrated circuits. As such integrated circuits become more complex, there is a need to increase the number of metal layers. To do so requires a total planarization scheme which planarizes not only small metal features but also large metal features such as bonding pad areas.

SUMMARY OF THE INVENTION

The present invention is a method of fabricating a semiconductor device comprising the step of defining metal interconnect features in a metal layer so that a metal feature having a size substantially larger than a predetermined feature size comprises an array of metal features. Each of the metal features in the array has a size not substantially larger than the predetermined feature size.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a top view of a typical prior art first layer metal.

FIG. 2 is a cross-section view of a typical prior art first layer metal covered by a typical prior art dielectric layer.

FIGS. 3a-3c are cross-sectional views of an implementation of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 shows top view of portion of typical prior art first layer metal. The metal shown contains a pad 10 which, for the purposes of illustration, is approximately 2.5 micons by 2.5 microns; pad 10 could be a contact area to either an underlying device structure or a subsequent metal layer. Leading from this pad is a metal runner 14 which, for the purposes of illustration, is 1-1.2 micon wide; runner 14 carries current from small contact pad 10 to a large bonding pad area which, for the purposes of illustration, is 100 microns by 100 microns in size. The metal thickness in such structures is typically 6,000 to 10,000 angstroms.

Many planarization techniques can be used to make a planar structure over at least portions of a typical prior art first metal layer. One technique is the use of bias sputtered quartz. The bias sputtered quartz process tends to planarize micron sized features very well; however, larger pad areas which are on the order of 10-100 microns or larger will not typically be planarized if the planarization process is set to planarize much smaller features such as contact pad 10.

FIG. 2 shows the typical profile of an oxide dielectric layer 14 over small metal feature 10 as well as over large bonding pad area 12 after typical prior art deposition of the dielectric. The figure illustrates the typical prior art result of RF bias sputtering used to deposit the dielectric, deposition and resputtering having been timed to planarize the dielectric region over small feature 10. The result is a substantial difference in oxide thickness above small feature 10 and larger feature 12. This creates a rough topologly which becomes a problem at via etch since, in order to clear the oxide dielectric from above pad area 12, small features such as pad 10 are exposed to a considerable overetch. This overetch causes problems such as polymer redeposition in vias and sputter damage of the underlying metal. Additionally, end point detection is very difficult to achieve.

A process sequence comprising the present invention is depicted in FIGS. 3a-3c. FIG. 3a shows a metal layer which could be at any desired level in a semiconductor device, e.g., first, second, third, or fourth level metal. The layer illustrated comprises a small metal feature such as a runner or contact pad 20 and a large bonding pad area which is made up of small metal features such as runners 22 in an array. The width of features or runners 22 is not substantially wider than the width of a predetermined feature size such as that of a minimum metal line width or a width of a small contact pad such as 20.

In FIG. 3a, bias sputtered quartz 24 has been deposited uniformly over the layer of metal. Because the large pad area is comprised of an array of metal features having a predetermined feature size not substantially larger than the size of feature 20, the resulting structure is a planarized layer of dielectric 24 having a planarized upper surface 25 defining a dielectric thickness 29 above the metal layer. The spacing between features 22 is not critical.

Next, an etch resist such as photoresist 26 is applied and patterned to open up the large pad area in region 27 as well as to open up the smaller runner or contact pad area 20. Vias are then opened, for example, by wet chemical or dry plasma etching.

Since dielectric thickness 29 is the same over small metal features 20 as well as over the large pad area, end point detection an uniformity of the etch will produce little overetch on the metal and only slight overetching of the oxide in the pad area. The metal/oxide step in the pad area is typically on the order of 1000 angstroms or less.

The next step, as illustrated in FIG. 3b, is to deposit metal plugs 28 and 30 to fill the vias to a depth substantially equal to thickness 29. This is accomplished by depositing a metal by any desired technique such as evaporation or sputtering with etch resist 26 still in place, thus yielding a self-aligned metal plug process. Photoresist 26 is then lifted off to remove metal 32 which was deposited on etch resist 26.

At this point, the device is completely planar and is ready for a next layer 34 of metal interconnection, which may or may not be formed in accordance with the present invention. Thus, the process described above may be continued for as many layers of metal as desired.

A variation of this process is to remove etch resist 26 after the via etch and then deposit additional metal layer 34 without going through the planarization plug process. While this variation does not give total planarization prior to additional metal 34 deposition, it is easier to manufacture since there is no lift off process needed. The planarization of the large pad area using this method still eliminates overetch of small vias.

Accordingly, the present invention comprises a method of fabricating a semiconductor device comprising the step of defining metal interconnect features in a metal layer so that a metal feature 12 having a size substantially larger than a predetermined feature size such as 20 comprises an array of metal features 22. Each of metal features 22 in the array has a size not substantially larger than the predetermined feature size of feature 20.

Semiconductor devices fabricated in accordance with the present invention have a metal interconnect feature which comprises an array of metal features 22, each of the metal features 22 in the array having a size not substantially larger than a predetermined feature size such as the size of a metal runner or contact area 20. The preferred embodiment of a semiconductor device fabricated in accordance with the present invention further comprises a metal plug 30 substantially covering the array.

In practicing the present invention, the feature size selected for planarization is a matter of design choice. For example, by selecting the predetermined feature size to be that of a contact area 20 having, for example, a size of 2.5 microns by 2.5 microns rather than selecting the predetermined feature size to be the size of a metal runner having, for example, a width of 1 micron, the planarization of dielectric layer 24 for the larger 2.5 micron feature size will also adequately planarize similarly sized or smaller features such as runners. Further, the array of metal features 22 can be of any configuration desired. For example, features 22 may be separate runners, connected runners, crossed runners, a serpentine pattern, or small squares or other shapes.

The present invention is to be limited only in accordance with the scope of the appended claims, since others skilled in the art may devise other embodiments still within the limits of the claims. 

The embodiments of the invention in which an exclusive property or right is claimed are defined as follows:
 1. A method of forming a substantially planar insulating layer over metal features on a semiconductor device, wherein said semiconductor device has an upper surface which is substantially planar, comprising the steps of:forming a plurality of said metal features directly on said upper surface, said metal features all being of substantially the same thickness, wherein at every point on each of said metal features, said metal feature is not substantially larger than a predetermined feature size in at least one direction parallel to said upper surface and wherein at least two of said metal features will operate together to perform the same function on said device; and bias sputtering an insulating layer over said metal features, wherein said predetermined feature size is such that the surface of said insulating layer opposite said upper surface will be substantially planar.
 2. The method of claim 1 wherein said predetermined feature size is ten microns.
 3. The method of claim 1 further including forming a connecting metal directly on said upper surface, wherein said connecting metal is substantially the same thickness as said metal features and at every point on said connecting metal said connecting metal is not substantially larger than said predetermined feature size in at least one direction parallel to said upper surface.
 4. The method of claim 1 wherein said upper surface is metal.
 5. The method of claim 1 wherein said upper surface is a semiconductor material.
 6. The method of claim 1 wherein said upper surface is a dielectric.
 7. A method of forming a substantially planar insulating layer over metal features on a semiconductor device, wherein said semiconductor device has an upper surface which is substantially planar, comprising the steps of:forming a plurality of said metal features directly on said upper surface, said metal features all being of substantially the same thickness, wherein at every point on each of said metal features, said metal feature is not substantially larger than ten microns in at least one direction parallel to said upper surface and wherein at least two of said metal features will operate together to perform the same function on said device; and forming an insulating layer over said metal features so that the surface of said insulating layer opposite said upper surface is substantially planar.
 8. The method of claim 7 wherein said upper surface is metal.
 9. The method of claim 7 wherein said upper surface is a semiconductor material.
 10. The method of claim 7 wherein said upper surface is a dielectric.
 11. The method of claim 7 wherein said insulating layer is formed by bias sputtering.
 12. A method of forming a substantially planar insulating layer over metal features on a semiconductor device, wherein said semiconductor device has an upper surface which is substantially planar, comprising the steps of:forming a plurality of said metal features directly on said upper surface, all from the same layer of metal, said metal features all being of substantially the same thickness, wherein at every point on each of said metal features, said metal feature is not substantially larger than a predetermined feature size in at least one direction parallel to said upper surface and wherein at least two of said metal features will operate together to perform the same function on said device; and bias sputtering an insulating layer over said metal features, wherein said predetermined feature size is such that the surface of said insulating layer opposite said upper surface will be substantially planar.
 13. The method of claim 1 wherein said predetermined feature size is ten microns. 